Polycrystalline diamond compact

Patent metadata

Field	Value
Publication number	US-10961785-B2
Application number	US-201916667597-A
Country	US
Kind code	B2
Filing date	Oct 29, 2019
Priority date	Oct 3, 2008
Publication date	Mar 30, 2021
Grant date	Mar 30, 2021

Abstract

In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.

First claim

The invention claimed is:

1. A polycrystalline diamond compact, comprising:
a polycrystalline diamond table, at least an unleached portion of the polycrystalline diamond table including:
a plurality of diamond grains bonded together via diamond-to-diamond bonding to define a plurality of interstitial regions, the plurality of diamond grains exhibiting an average grain size of about 10 μm to about 50 μm;
a catalyst occupying at least a portion of the plurality of interstitial regions; and
a coercivity greater than about 115 Oe to about 250 Oe.

2. The polycrystalline diamond compact of claim 1 , wherein the average grain size of the plurality of diamond grains is about 10 μm to about 30 μm.

3. The polycrystalline diamond compact of claim 2 , wherein the average grain size of the plurality of diamond grains is about 10 μm to about 18 μm.

4. The polycrystalline diamond compact of claim 1 , wherein the coercivity of the unleached portion of the polycrystalline diamond table is about 115 Oe to about 175 Oe.

5. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table exhibits one or more characteristics of being sintered at a cell pressure of about 7.5 GPa to about 15 GPa.

6. The polycrystalline diamond compact of claim 1 , wherein the unleached portion of the polycrystalline diamond table exhibits a specific magnetic saturation of greater than 0 G·cm 3 /g to about 15 G·cm 3 /g.

7. The polycrystalline diamond compact of claim 6 , wherein the specific magnetic saturation of the unleached portion of the polycrystalline diamond table is about 10 G·cm 3 /g to about 15 G·cm 3 /g.

8. The polycrystalline diamond compact of claim 7 , wherein the unleached portion of the polycrystalline diamond table exhibits a specific permeability of less than about 0.10 G·cm 3 /g·Oe.

9. The polycrystalline diamond compact of claim 8 , wherein the specific permeability of the unleached portion of the polycrystalline diamond table is about 0.6 G·cm 3 /g·Oe to about 0.9 G·cm 3 /g·Oe.

10. The polycrystalline diamond compact of claim 8 , wherein the unleached portion of the polycrystalline diamond table exhibits a G ratio of at least about 4.0×10 6 .

11. The polycrystalline diamond compact of claim 10 , wherein the G ratio , of the unleached portion of the polycrystalline diamond table is about 5.0×10 6 to about 15.0×10 6 .

12. The polycrystalline diamond compact of claim 8 , wherein the polycrystalline diamond table exhibits a thermal stability, as determined by a distance cut, prior to failure, in a vertical lathe test of about 1300 m to about 3950 m.

13. A rotary drill bit, comprising:
a bit body including a leading end structure configured to facilitate drilling a subterranean formation; and
a plurality of cutting elements mounted to the bit body, at least one of the plurality of cutting elements including the polycrystalline diamond compact according to claim 1 .

14. The polycrystalline diamond compact of claim 1 , wherein at least the unleached portion of the polycrystalline diamond table includes a catalyst content of the catalyst of about 1 weight % to about 7.5 weight %.

15. A polycrystalline diamond compact, comprising:
a polycrystalline diamond table, at least an unleached portion of the polycrystalline diamond table including:
a plurality of diamond grains bonded together via diamond-to-diamond bonding to define interstitial regions, the plurality of diamond grains exhibiting an average grain size of about 10 μm to about 30 μm;
a catalyst including cobalt, the catalyst occupying at least a portion of the interstitial regions;
a coercivity of about 115 Oe to about 250 Oe; and
a specific magnetic saturation of about 5 G·cm 3 /g to about 15 G·cm 3 /g or less; and

a substrate bonded to the polycrystalline diamond table along an interfacial surface.

16. The polycrystalline diamond table of claim 15 , wherein the unleached portion of the polycrystalline diamond table exhibits a G ratio of at least about 4.0×10 6 .

17. A rotary drill bit, comprising:
a bit body including a leading end structure configured to facilitate drilling a subterranean formation; and
a plurality of cutting elements mounted to the bit body, at least one of the plurality of cutting elements including the polycrystalline diamond compact according to claim 15 .

18. The polycrystalline diamond compact of claim 15 , wherein at least the unleached portion of the polycrystalline diamond table includes a catalyst content of the catalyst of about 1 weight % to about 7.5 weight %.

19. A polycrystalline diamond compact, comprising:
a polycrystalline diamond table sintered exhibiting one or more characteristics of being sintered at a cell pressure of at least about 7.5 GPa, at least an unleached portion of the polycrystalline diamond table including:
a plurality of diamond grains bonded together via diamond-to-diamond bonding to define interstitial regions, the plurality of diamond grains exhibiting an average grain size of about 10 μm to about 18 μm;
a catalyst including cobalt, the catalyst occupying at least a portion of the interstitial regions;
a coercivity of about 115 Oe to about 175 Oe;
a specific magnetic saturation of about 10 G·cm 3 /g to about 15 G·cm 3 /g; and
a specific permeability of less than about 0.10 G·cm 3 /g·Oe; and

a substrate bonded to the polycrystalline diamond table along an interfacial surface.

20. The polycrystalline diamond table of claim 19 , wherein the unleached portion of the polycrystalline diamond table exhibits a G ratio of at least about 4.0×10 6 .

21. The polycrystalline diamond compact of claim 19 , wherein the specific permeability of the unleached portion of the polycrystalline diamond table is about 0.6 G·cm 3 /g·Oe to about 0.9 G·cm 3 /g·Oe.

22. The polycrystalline diamond compact of claim 19 , wherein the polycrystalline diamond table exhibits a thermal stability, as determined by a distance cut, prior to failure, in a vertical lathe test of at least about 1300 m.

23. A rotary drill bit, comprising:
a bit body including a leading end structure configured to facilitate drilling a subterranean formation; and
a plurality of cutting elements mounted to the bit body, at least one of the plurality of cutting elements including the polycrystalline diamond compact according to claim 19 .

24. The polycrystalline diamond compact of claim 19 , wherein at least the unleached portion of the polycrystalline diamond table includes a catalyst content of the catalyst of about 3 weight % to about 7.5 weight %.

Assignees

• Us Synthetic Corp

Inventors

• Bertagnolli Kenneth E
• Miess David P
• Qian Jiang
• Wiggins Jason K
• Vail Michael A
• Mukhopadhyay Debkumar

Classifications

• B22F7/08 Primary

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• E21B23/0419

  using down-hole motor and pump arrangements for generating hydraulic pressure · CPC title

• E21B10/567 Primary

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title

• B22F2998/00

  Supplementary information concerning processes or compositions relating to powder metallurgy · CPC title

• E21B10/5735

  Interface between the substrate and the cutting element · CPC title